Zonegreen
Rail Depot and Workshop Safety Technology

Davy Industrial Park,
Prince of Wales Road,
Sheffield,
S9 4EX,
United Kingdom
Delivering intelligent technologies to offer protection from dangerous environments in a safe and efficient manner.
Zonegreen’s team of experts has developed an impressive range of intelligent technologies to offer safety-related products and innovative planning of train maintenance operations, and has forged an unrivalled reputation for quality, safety and reliability.
Depot personnel protection systems, interlocking solutions, as well as railway maintenance planning applications and out-of-gauge warning systems are installed worldwide and can be used in sectors as diverse as transport, petrochemicals and aerospace.
Depot personnel protection system
The Depot Personnel Protection System, commonly referred to as the Depot Protection System, is specialised and designed to ensure the safe and controlled movement of rail vehicles into and out of depots, so that maintenance operations can be conducted without endangering staff or the depot infrastructure.
Zonegreen’s SMART DPPS™ is highly advanced, state-of-the-art and incorporates intelligent, distributed communication technology, as well as electronic personnel datakeys to uniquely identify staff working in different safety zones.
The Zonegreen’s SMART DPPS™ allows the user to:
- Login from any convenient point of access using a unique personnel datakey, replacing the need for padlocks
- Easily identify personnel who are logged onto different roads
- Interlock with other third-party equipment/systems to prevent unsafe movement
- Protect working staff and other interlocked equipment from vehicle movement
- Capture personnel logon/logout and movement history for future audit purposes
Additionally, where overview software is included, the status of Zonegreen’s SMART DPPS™ and personnel logged on will be visualised graphically from the depot manager’s office via a wall display.
Points converter for powering manual points
Designed to increase railway depot and workshop safety and efficiency, the Zonegreen Convertor allows the automation and remote operation of manual / hand points switches and rail road crossings.
Benefits of powering your manual points
- Enhanced safety by reducing the potential for slips, trips and falls
- Increased depot efficiency and speeding up of operations by eliminating many stops and starts
- Expandable: routes can be pre-set, re-configured and upgraded at any time
- Traceability includes an event logging system that allows the depot manager to keep a record of the points operation
- Low cost
- LUL approved
The Zonegreen convertor system comprises two parts:
- Point Machine Conversion System: a point machine conversion device is attached to an existing manually-operated switch without compromising the integrity of the existing mechanism. It does not require any civil works or changes in the operating procedures to be installed. Each converter can be used as a stand alone or multiple units can be installed operating together with routing
- Radio Remote Operator’s Controller: an intuitive handset that allows the operator to remotely control the points system. It can be either hand portable or cab mounted. A centralised control system is also available via windows PC interface that offers route planning and visualisation. The radio controller can also be used in a route selection mode, whereby one command can operate several points and crossings simultaneously
Train maintenance planner
The planning of train maintenance operations is still commonly conducted on a big whiteboard located in the operations control room, on which the train units that require servicing, maintenance tasks, arrival and departure times are listed. These are updated manually either in a tabular form or on top of a graphical layout representing a bird’s eye view of the depot.
Zonegreen’s depot manager, as a multi-user, web-based graphical task planning application, is a cost-effective replacement of the whiteboard. It consists of two main views: a graphical layout representing the depot on which users can position trains and create and assign maintenance tasks, and a tabular layout to plan trains’ scheduled arrivals and departures.
The train maintenance function of the depot manager allows staff to:
- Plan train-unit maintenance activities
- Easily visualise train locations in graphical layout
- Accurately update and synchronise maintenance information
- Share and disseminate maintenance information to different locations in a convenient way
- Capture maintenance activities and generate reports, reducing the manual tasks of filling in maintenance forms and paperwork
Safety interlocking systems
The concept of interlocking has been applied to create increasingly sophisticated systems with the potential to prevent personal injury or costly damage. These systems can stop unauthorised train movements or actions by personnel not following stipulated safety procedures.
A typical installation is vastly superior to a permit to work system (which depends on personnel obeying written rules); physically prevents access to high-level working platforms while overhead line equipment remains live; isolates power to overhead crane while OLE is live; and ensures a safe system of work.
Out-of-gauge warning system
Zonegreen’s out-of-gauge warning system has been developed in response to rail industry demand for a ‘gold standard’ in obstacle detection systems. It is based around a series of non-contact laser rangefinder sensors and prevents a train from leaving the depot if its side skirt has not been fully closed.
If the sensor detects any kind of obstruction, for example an open side skirt, it will trigger an alert on the outbound visual warning board and illuminate a driver warning stop board on the depot exit road. The stop signs will remain illuminated until the warning is reset via the master keyswitch.
The out-of-gauge warning system is flexible and has a range of programmable options, such as a delayed response to help prevent the triggering of false alerts. It may also be expanded to cover the entire side area of the vehicle using a multiple sensor arrangement.
Depot safety-related equipment
Zonegreen offers a range of safety-related equipment for depots, including but not limited to:
- Ground position signals
- High level or pit warning beacons – static or flashing
- Klaxons
- Speed indication detectors
- Stop and proceed boards
- Electronic wheel-detect switches (treadle switch)
- Portable warning systems
Maintenance and installation works at rail and tram facilities
Zonegreen is now able to undertake additional servicing maintenance and installation works at rail and tram maintenance facilities (IRSE installers) in addition to its normal servicing of depot personnel protection and interlocking systems. Zonegreen now offers the following:
- Points / switches
- Track circuit renewal (IRSE licensed)
- Signal including axle counters
- Cable testing (SMTH standards)
- Barrier systems
- AWS & TPWS systems
Zonegreen Provides Sidings Protection at Local Depot
The rail safety specialists have installed a siding warning system at Hitachi Rail’s Doncaster Carr, to counter the risks posed by work being carried out on the service spine.
26 January 2022Zonegreen Leads Safety Drive in Scottish Depots
Rail safety specialist, Sheffield-based Zonegreen, has completed the first in a series of planned depot enhancements for Scottish railway operator, ScotRail.
6 October 2021Zonegreen Transports Historic Depot to Cutting Edge
Zonegreen has installed its very latest rail safety technology at a depot famed for servicing steam locomotives.
30 July 2021Zonegreen Depot Safety on Right Wavelength
Rail safety specialist Zonegreen has launched the MK III control panel for its flagship depot protection system that uses the latest contactless technology.
20 December 2020Zonegreen Protects Staff at Tyne and Wear Metro’s £8.4m Learning Centre
Employees entering Tyne and Wear Metro depots are now fully trained in personal protection, thanks to Sheffield-based Zonegreen.
30 November 2020Zonegreen Celebrates Milestone Order
Sheffield-based rail industry specialist Zonegreen is marking a major milestone in its 12-year history, the 2,000th order of its depot safety equipment.
31 October 2020Zonegreen Completes Third Installation in Australia
A Sydney rail depot has become the first in New South Wales and third across Australia to call on Sheffield safety specialist Zonegreen to improve working conditions for staff.
30 September 2020Zonegreen Extends Depot Safety at Ardwick
Zonegreen is helping the Ardwick depot in Manchester, UK, prepare for the first wave of a £500m fleet of trains, set to replace the much-maligned Pacers.
31 July 2020Zonegreen Extends Reach Across Emerald Isle
Zonegreen is expanding its presence in the Republic of Ireland, after installing a new warning system at Dublin’s Fairview Depot.
1 April 2020Zonegreen Reaches Midpoint in Major Norwich Project
Zonegreen is equipping Norwich’s Crown Point depot with its latest personnel protection technology as part of a £40m upgrade.
18 March 2020Zonegreen Completes Phase Two of DPPS Installation at Crown Point in Norwich
UK-based rail safety specialist Zonegreen is equipping Norwich’s Crown Point depot with its latest personnel protection technology, as part of a £40m upgrade.
11 March 2020Zonegreen Upgrades Technology at Siemens’ Northam Depot
Yorkshire-based rail safety company Zonegreen has upgraded its technology at a second Siemens depot in the UK.
21 February 2020Zonegreen Upgrades Technology at Second Siemens UK Depot
Zonegreen has upgraded its technology at a second Siemens UK depot as part of a major midlife overhaul programme.
15 January 2020Zonegreen to Supply DPPS to Second Australian Facility
Zonegreen has been chosen by Australia’s Downer Group to supply worker protection technology at a second train maintenance facility.
3 December 2019Zonegreen Supplies Personnel Protection System for Nexus Rail Skills Centre
Zonegreen is to supply its flagship technology to Metro operator Nexus’ £8.4m training facility, which is being constructed in South Shields, UK.
28 October 2019Leading Rail Expert Marks 20 Years at Zonegreen
Zonegreen is celebrating the achievements of its technical director, who has been driving up safety standards within the rail industry for the last two decades.
11 September 2019Zonegreen Operates with Siemens on Major Safety Upgrade
Zonegreen, the Sheffield-based rail safety specialist, is working with Siemens to renovate the personnel protection systems installed at its UK maintenance depots.
5 August 2019Zonegreen Works With Depot Safety In Doha
Zonegreen is assisting the workers who are helping to develop one of the Middle East’s most high-profile transport projects with a level of safety to match.
24 June 2019Zonegreen Provides Technology for Crown Point Safety Upgrades
Zonegreen is providing advanced technology for the Crown Point rail depot in Norwich, UK, designed to prevent accidents and offer protection to staff.
15 April 2019Zonegreen Highlights Safety for Earthing Procedures at Depots
Zonegreen is urging depot operators to review their earthing procedures to ensure personnel working with overhead lines are adequately protected.
15 March 2019Zonegreen Provides Depot Safety System for Doha Metro
Staff working on Qatar’s advanced driverless metro in Doha will be among the safest in the world with innovative depot protection technology from Zonegreen.
3 December 2018Zonegreen Ensures Staff Safety at Willesden Depot
Zonegreen's flagship technology has been installed for staff working the overground fleet in London, UK, in order to avoid accidents when carrying out maintenance at height.
31 October 2018Zonegreen System Ensures Train Depot Safety in Banbury
A new and advanced railway maintenance facility in Banbury, Oxfordshire, UK, is operating smoothly and safely with Zonegreen’s Depot Personnel Protection System™ (DPPS).
26 September 2018Zonegreen Signs Safety Maintenance Contract
Zonegreen has finalised a five-year deal with Bombardier that will safeguard workers looking after London’s new Elizabeth line trains.
28 August 2018Zonegreen Makes Inroads into Train Modernisation
Zonegreen has installed its first main Depot Personnel Protection System (DPPS™) at a UK train building facility.
21 August 2018Zonegreen Provides DPPS™ for Train Modernisation Centre
Zonegreen has recently installed its first flagship Depot Personnel Protection System (DPPS™) at Alstom's train manufacturing facility in the UK.
30 July 2018Australia Shows Faith in Zonegreen Safety System
22 November 2016Zonegreen Chosen to Safeguard Intercity Depots
29 September 2015Zonegreen Develops Smarter Depot System
29 July 2015Zonegreen Wins Siemens Supplier Recognition
22 July 2015Zonegreen Celebrates Landmark Order
17 July 2015Zonegreen Points Shunter Safety in Right Direction
16 July 2015Zonegreen Boosts New Zealand’s Railway Safety
15 January 2014Zonegreen Protects Depot by Reading Between Lines
3 September 2013Alstom Selects Zonegreen for Hi-Tech Italian Railway Depot
9 May 2013Zonegreen Helps Future Proof Modernised Rail Depot
21 March 2013High Demand for Innovative Safety Solutions
5 March 2013Unique and Ultra-Safe Powered Derailer has Received Network Rail Approval
1 February 2013Zonegreen Wins Safety Contract with Australia’s Biggest Rolling Stock Provider
21 March 2012Zonegreen Launches New Generation Points Converter for Greater Efficiency and Safety
31 August 2011Alstom Invite UK Rail Safety Experts to Upgrade Depot Protection
5 July 2011Zonegreen Presents New Product – Closing Force Monitor
9 June 2011Zonegreen is Maintenance-Ready as Always
8 June 2011Leading-Edge Safety Technology for New Zealand Rail Network Development
14 April 2011Zonegreen Wins KiwiRail Safety Contract
8 November 2010Zonegreen Wins Safety Contract for Dubai Metro
26 April 2010Zonegreen Releases Latest ‘Skirt Detector’ Safety Innovation
8 April 2010New-Generation Derailer Launched
15 March 2010Zonegreen Offers ‘Safety First’ Service for Depot Personnel Protection Systems (DPPS)
2 February 2010Zonegreen Launches its Products in the Australian Market
24 November 2009Zonegreen to Attend AusRail 2009
11 November 2009Zonegreen Launches State-of-the-Art Traincare Depot Planning Tool
13 October 2009Zonegreen
- Gemma Houghton (Sales & Marketing Manager)
- +44 114 230 0822
- +44 871 872 0349
- gemmah@zonegreen.co.uk
- info@zonegreen.co.uk
- Depot Protection
- Railway Points Converter
- Planning Electronic Whiteboard
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